Modular vehicle

ABSTRACT

A passenger compartment of the modular vehicle, such as a bus, includes a roof panel and sandwich-type side panels coupled to structural joiners to form the passenger compartment. The side panels and the joiners may include pultruded beams for increased structural integrity. A chassis of the vehicle has channels integrated therein for coupling of the side panels and passenger compartment to the chassis. This coupling to the chassis channel may also include the use of a bonding agent.

FIELD

The present disclosure generally relates to vehicles, and moreparticularly to an improved modular vehicle and methods of assemblythereof.

BACKGROUND

Typically, multi-passenger buses and other vehicles are constructed of achassis onto which a frame, often made of metal such as steel, is built.Attached onto the frame are exterior panels, which are often aluminum orfiberglass. Interior panels are attached to the frame to form theinterior of the vehicle.

Multi-passenger vehicles, since they carry passengers that often do notwear restraints such as seatbelts, are subject to rigorous safety andcrash test standards. However, since the frame is rigid and the panelsare made of malleable, brittle materials, a crash or rollover of thevehicle results in the panels and frame deforming and/or breaking,causing serious injury to passengers. This results in a limited residualspace (i.e., a survival zone for passengers) within the passengercompartment of the bus or vehicle.

Reinforcement measures have been implemented to increase the structuralintegrity of present frames and panels. For example, steel plates orother heavy, durable materials are appended to the frame and/or panelsto increase their structural integrity.

Moreover, sandwich type panel constructions have also been used, such asto build recreational vehicles. These include a sandwich panel corematerial such as polystyrene, paper, metal honeycomb, foamedpolyurethane, plywood, or fibrous boards. A sandwich panel facingmaterial (such as steel, aluminum, plywood, hardboard, orfiberglass-reinforced plastic) is then bonded to the core materials andany reinforcing member. Another sandwich panel facing material may alsobe bonded to the core materials on the opposite side as the sandwichpanel facing material. A support member can then be secured using afastener to an outside of the sandwich panel at the reinforcing member.

However, these reinforcement techniques (i.e., steel plates and sandwichtype panels) cause the multi-passenger vehicles to become excessivelyheavy, creating issues regarding Gross Vehicle Weight. Moreover, knownsandwich type panels often insufficiently provide structural support tothe vehicle, thereby still resulting in deformation and breakage uponimpact during a crash, roll-over, etc.

SUMMARY

In general, the present disclosure relates to an improved modularvehicle, such as a paratransit passenger bus, optimally configured tosatisfy weight and strength considerations, and methods for assemblingthe modular vehicle. A passenger compartment of the modular vehicle,such as a bus, includes a roof panel and sandwich-type side panelscoupled to structural joiners to form the passenger compartment. Theside panels and the joiners may include pultruded beams for increasedstructural integrity. A chassis of the vehicle has channels integratedtherein for coupling of the side panels and passenger compartment to thechassis. This coupling to the chassis channel may also include the useof a bonding agent.

The modular vehicle, according to the disclosure, has an increasedresidual space. Gross vehicle weight is reduced over steel frame vehiclestructures, while structural integrity is improved.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of devices, systems, and methods are illustrated in thefigures of the accompanying drawings which are meant to be exemplary andnot limiting, in which like references are intended to refer to like orcorresponding parts, and in which:

FIG. 1A illustrates a perspective view of a modular vehicle according toembodiments of the disclosure;

FIG. 1B illustrates a perspective view of components of the modularvehicle according to embodiments of the disclosure;

FIG. 1C illustrates a perspective view of a passenger compartment of themodular vehicle according to embodiments of the disclosure;

FIG. 1D illustrates a cross-section view of the passenger compartment ofthe modular vehicle according to embodiments of the disclosure, takenalong the line AA of FIG. 1C;

FIG. 2A illustrates an exploded view of a chassis coupled to a sidepanel according to embodiments of the disclosure;

FIG. 2B illustrates the chassis coupled to the side panel according toembodiments of the disclosure;

FIG. 2C illustrates the chassis decoupled from the side panel accordingto embodiments of the disclosure;

FIG. 2D illustrates a perspective view of an embodiment of the chassiscoupled to the side panel according to embodiments of the disclosure;

FIG. 2E illustrates a perspective view of another embodiment of thechassis coupled to the side panel according to embodiments of thedisclosure;

FIG. 3 illustrates an exploded view of the side panel according toembodiments of the disclosure;

FIG. 4 illustrates a perspective view of the side panel according toembodiments of the disclosure with structural pultrusions shown inphantom;

FIG. 5 illustrates a side view of the side panel incorporating cuttinglines according to embodiments of the disclosure with structuralpultrusions shown in phantom;

FIG. 6 illustrates a perspective view of the cut side panel according toembodiments of the disclosure with structural pultrusions shown inphantom;

FIG. 7 illustrates an enlarged view of a first portion of the cut sidepanel of FIG. 6 according to embodiments of the disclosure;

FIG. 8 illustrates an enlarged view of a second portion of the cut sidepanel of FIG. 6 according to embodiments of the disclosure;

FIG. 9 illustrates a cross-section view of a joiner coupled to the sidepanel of FIGS. 3 through 8 and a roof panel according to embodiments ofthe disclosure

FIG. 10 illustrates a side view of the roof panel according toembodiments of the disclosure;

FIG. 11 illustrates a system for constructing a panel according toembodiments of the disclosure;

FIG. 12 illustrates an alternative system for constructing a panelaccording to embodiments of the disclosure;

FIG. 13 illustrates an alternative system for constructing a panelaccording to embodiments of the disclosure;

FIG. 14A illustrates orthogonal pultrusions according to embodiments ofthe disclosure;

FIG. 14B illustrates orthogonal pultrusions with one of the pultrusionshaving a hole cut therethrough according to embodiments of thedisclosure;

FIG. 14C illustrates an insert for coupling orthogonal pultrusionsaccording to embodiments of the disclosure;

FIG. 14D illustrates orthogonal pultrusions coupled using the insert ofFIG. 14C according to embodiments of the disclosure;

FIG. 15A illustrates orthogonal pultrusions coupled using a bracketaccording to embodiments of the disclosure;

FIG. 15B illustrates orthogonal pultrusions coupled using the bracketaccording to embodiments of the disclosure;

FIG. 16A illustrates a tee-bracket for coupling pultrusions according toembodiments of the disclosure;

FIG. 16B illustrates a pultrusion having a portion removed from an endthereof for coupling pultrusions using the tee-bracket of FIG. 16Aaccording to embodiments of the disclosure;

FIG. 16C illustrates pultrusions coupled using the tee-bracket of FIG.16A according to embodiments of the disclosure;

FIG. 16D illustrates pultrusions coupled using the tee-bracket of FIG.16A according to embodiments of the disclosure;

FIG. 16E illustrates pultrusions coupled using the tee-bracket of FIG.16A according to embodiments of the disclosure;

FIGS. 17A-17M illustrate major aspects of construction of a modularparatransit bus according to the disclosure; and

FIG. 18 is a flow diagram illustrating steps in a method to construct amodular vehicle according to the disclosure.

DETAILED DESCRIPTION

Detailed embodiments of devices, systems, and methods are disclosedherein, however, it is to be understood that the disclosed embodimentsare merely exemplary of the devices, systems, and methods, which may beembodied in various forms. Therefore, specific functional detailsdisclosed herein are not to be interpreted as limiting, but merely as abasis for the claims and as a representative basis for teaching oneskilled in the art to variously employ the present disclosure.

In general, the present disclosure provides an improved modular vehicleand methods for assembling the modular vehicle. The modular vehicle isoptimally configured to satisfy weight and strength considerations. Apassenger compartment of the modular vehicle includes a roof panel andsandwich-type side panels coupled to joiners using a bonding agent, suchas resin. Both side panels and the joiners include pultruded beams forincreased structural integrity. A chassis of the vehicle has channelsintegrated therein for coupling of the panels to the chassis using abonding agent, for example. As a result, the modular vehicle has anincreased residual space.

Referring to FIGS. 1A through 1D, a modular vehicle 101 having a modularpassenger compartment 100 according to the present disclosure isdescribed. The modular vehicle 101 includes a driver compartment 103coupled to the passenger compartment 100 and/or a chassis 102 using afastener such as an adhesive, resin, epoxy, or the like. The drivercompartment 103 may be bonded to a front panel 105 of the passengercompartment 100.

The passenger compartment 100, which couples to a portion of the chassis102, is formed of two sandwich-type side panels 104 that are eachcoupled at or proximate an edge of the chassis 102, joiners 106 that areeach coupled to an edge of a side panel 104, and a roof panel 108coupled to the joiners 106. As illustrated (best illustrated in theperspective view of FIG. 1C), each joiner 106 spans the length (front toback) of the passenger compartment 100. However, one skilled in the artshould appreciate the joiners 106 could be configured having lengths notcommensurate in scope with lengths of the passenger compartment 100. Forexample, each joiner 106 may have a length shorter than that of thepassenger compartment 100, thereby resulting in more than one joiner 106being used on each side of the passenger compartment 100 in order tocover the length of the passenger compartment 100. In this alternativeconstruction, a seal would be introduced between each section of joiner106.

FIGS. 1D, 2A through 2C illustrate the chassis 102 coupled to the sidepanel(s) 104. The chassis 102 includes a channel(s) 200, such as a Uchannel, for example. The channel 200 is formed by a first side 203, abottom portion 205, and a second side 207. The channel 200 may or maynot have a length commensurate with the length of the chassis 102 and/orside panel 104 but in most implementations that may be desirable. Theside panel 104 is coupled to the channel 200 of the chassis 102. Suchcoupling may include the use of a bonding agent, such as resin, epoxy,or the like. For example, the side panel 104 may be coupled to thechassis 102 (i.e., the first side 203, the bottom portion 205, and/orthe second side 207) using a one (1) component polyurethane adhesive,such as Sikaflex® 252 or 255, offered by Sika Corporation of Lyndhurst,N.J. Neither, one, or both of the sides 203, 207 may have one or moreangled edges 202 that provide structural integrity to the channel 200and/or provide a guide mechanism to help guide the edges of the sidepanels 104 into the channel 200 during assembly of the compartment tothe chassis 102. The angled edges 202 may also provide increased surfacearea for bonding of the side panels 104 to the channel 200. Although notshown, it should be appreciated that edges of the side panel may havemechanical structures such as bumps or detents to mate withcorresponding mechanical features formed in the chassis channel in orderto provide a friction fit and supplement a bonding agent in attachingthe compartment/side panels to the chassis.

FIG. 2D illustrates a specific embodiment for coupling the side panel104 to the chassis 102. According to this embodiment, the channel 200 isformed by two portions (i.e., the bottom portion 205 and the first side203). The first side 203 may be an interior side of the channel 200.That is, the first side 203 may abut a surface of the side panel 104that faces an interior of a fully constructed modular vehicle asdescribed herein. The side panel 104 may be coupled to the bottomportion 205 and/or the first side 203 using a bonding agent, such asresin, epoxy, or the like.

FIG. 2E illustrates another specific embodiment for coupling the sidepanel 104 to the chassis 102. According to this embodiment, the channel200 is formed by two portions (i.e., the bottom portion 205 and thesecond side 207). The second side 203 may be an exterior side of thechannel 200. That is, the second side 207 may abut a surface of the sidepanel 104 that forms an outer surface of a fully constructed modularvehicle as described herein. The side panel 104 may be coupled to thebottom portion 205 and/or the second side 207 using a bonding agent,such as resin, epoxy, or the like.

Referring now to FIGS. 3 and 4, a side panel 104 according to thepresent disclosure is described. Side panels may be configured andconstructed as described in detail in commonly owned, co-pending U.S.patent application Ser. No. 14/739,569 filed Jun. 15, 2015, which isincorporated herein by reference in its entirety, filed by the sameinventors as the present application. The panel 104 includes a firstouter sheet 302, a second outer sheet 304, one or more pultruded boxbeams or “pultrusions” 306 disposed between the first outer sheet 302and the second outer sheet 304, and one or more core material portions308 disposed between the first outer sheet 302 and the second outersheet 304. In an example, the panel 104 may be a modular panelconfigured for use in a paratransit passenger bus. Accordingly, thepanel 104 may be about 169 inches by about 81 inches, for example.

The first and second outer sheets 302, 304 may be monolithically formedas single pieces, and act as a type of skin of the panel 104. Forexample, the first and second outer sheets 302, 304 may be fiberreinforced plastic or fiber reinforced polymer (FRP). The outer sheets302, 304 may also be coated, embossed, laminated, or otherwise providedecorative appeal to the panel 104.

The one or more pultruded box beams 306 may be disposed in selectedlocations between the first and second outer sheets 302, 304 to providenecessary weight, strength, and structural aspects to the panel 104. Asillustrated, the panel 104 is designed to be used as a side panel for amodular vehicle, such as a bus or paratransit bus, so the pultruded boxbeams 306 are optimally sized for strength and structural weightconsiderations. For example the pultrusions 306 could be square orrectangular, or the like, and dimensioned to be from about 1 to 3 inchesby about 1 to 3 inches formed as square or rectangular beams to providedesired strength and weight characteristics for the illustrativeparatransit bus side panel implementation. In an illustrativeembodiment, the pultrusions 306 may be 1.5 inch by 1.5 inch squarebeams. In this example, the one or more box beams 306 include foursubstantially vertical portions 310 and two substantially horizontalportions 312. The four substantially vertical portions 310 are spacedapart from one another along a horizontal length of the panel 104 at adistance in a range of approximately 30 to 55 inches, or otherwisespaced for window placement and to maintain structural integrity.

Similarly, the two horizontal sections 312 of the pultruded box beams306 are optimally sized for strength and structural weightconsiderations. The horizontal pultrusions 312 are positioned below acenter line of the panel 104 at a distance between each pultrusion in arange of approximately 30 to 55 inches. This allows for windows andother features of a side of the modular vehicle to be formed utilizingthe load carrying characteristics of the integrated frame and side panel104 without the weight and complexity of welded metal framing.

The core material 308 may fill the space between the first and secondouter sheets 302, 304, as well as between the various pultruded boxbeams 306. The core material 308 may be a foam, or other lightweight,durable material, such as high-density and closed-cell foam. In anexample, when the core material 308 is a solid type material, the corematerial 308 may include one or more portions disposed between thehorizontal and vertically disposed pultruded box beams 306. In anotherexample, when the core material 308 is a solid type material, the corematerial 308 may include recesses or channels 314 formed therein, inwhich case the box beams 306 are disposed in the channels 314.

In one example, the side panel 104 may be formed by coupling the firstouter sheet 302 to a first side of the box beams 306 and coupling thesecond outer sheet 304 to a second side, opposite the first side, of thebox beams 306. The core material 308 may then be injected between thefirst and second outer sheets 302, 304 and the box beams 306. In anotherexample, the panel 104 may be formed by positioning the box beams 306 inchannels 314 and coupling the box beams 306 to the core material 308.The first outer sheet 302 is then coupled to a first side of the boxbeams 306 and core material 308 and the second outer sheet 304 is thencoupled to a second side, opposite the first side, of the box beams 306and core material 308.

In yet another example, the panel 104 may be formed by positioning thebox beams 306 between sheets or portions of the core material 308 andcoupling the box beams 306 to the core material 308. The first outersheet 302 is then coupled to a first side of the box beams 306 and corematerial 308 and the second outer sheet 304 is then coupled to a secondside, opposite the first side, of the box beams 306 and core material308, as described in greater detail hereinafter.

The various elements (the first outer sheet 302, the second outer sheet304, the box beams 306, and the core material 308) may be coupledtogether via bonding to construct a side 104 panel with an integratedstructural frame. This may include bonding using one or more bondingagents, such as, adhesives, resins, etc.

As mentioned above, the panel 104 is designed to be used as alightweight structural side panel with an integrated frame for a modularvehicle, such as a bus or paratransit bus. For example, in FIG. 5, aparatransit bus side panel 104 with an integrated structural frame isillustrated having outlines for one or more windows 500 and a wheel well502 to be cut out after the modular side panel 104 is assembled asdescribed hereinafter. The one or more windows 500, wheel well 502, anda perimeter 504 of the side panel 104 may then be cut, resulting in theside panel 104 illustrated in FIG. 6 having a fully integratedstructural frame comprised of vertical and horizontal box beampultrusions 310, 312 as described herein before. In this example, thewindows 500 are located between the four vertically oriented box beams310 and vertically above the horizontally positioned box beams 312. Thisallows the side panel 104 of the vehicle to be constructed as a modularpanel with integrated structural components without compromising thestructure of the vehicle. However, it should be appreciated, that boxbeams 306 may be oriented in any of various directions and spacings toaccommodate other features of a side panel 104 of a vehicle or modularapplication to be formed with fully integrated structural componentscomprising the box beams 310, 312.

Referring to FIGS. 7 and 8, the box beams 306 provide for increasedstrength as well as a lighter side wall of a vehicle than that of anyconventional vehicle side wall construction. As illustrated in FIG. 8,the modular side panel 104 also allows for a greater radius in thewindows 500 than that of conventional vehicle side wall construction.This greater radius in the window 500 provides increased strength atwindow connections.

Referring now to FIG. 9, the joiner 106 for connecting a roof panel andside panels to form a modular vehicle according to the presentdisclosure is described. The joiner may be configured and constructed asdescribed in detail in commonly owned, co-pending U.S. patentapplication Ser. No. 14/806,730, filed Jul. 23, 2015, which isincorporated herein by reference in its entirety, filed by the sameinventors as the present application. The joiner 106 includes an innerextrusion 900, an outer extrusion 902, and optionally one or morepultruded box beams 306. The inner and outer extrusions 900, 902 may becoated, embossed, laminated, or otherwise provide decorative appeal tothe joiner 106.

The inner extrusion 900 is an arcuate structure having an arcuate orcurved surface 904 that is convex with respect to an inner passengercompartment when implemented. Furthermore, one or more support channels901, 903, 905, 907 are created along the curved surface 904 by walls909, 911, 913, 915, 917, 919 that extend from the curved surface 904.For example, these walls 909, 911, 913, 915, 917, 919 mayperpendicularly extend from the curved surface 904. Moreover, the curvedsurface 904 may have at least one substantially linear or planar surfacefrom which the walls 909, 911, 913, 915, 917, 919 extend. One or morebox beam channels 903, 905 may be created by the walls 909, 911, 913,915, 917, 919 proximate to ends of the curved surface 904. Additionally,a side panel channel 901 is created proximate to or at an end of thecurved surface 904 and a roof panel channel 907 is created proximate orat a different end of the curved surface 904. One or both of thesidewall panel and roof panel channels 901, 907 may be partially createdby the curved surface 904 and partially created by a wall 909, 919 of aproximate box beam channel 903, 905.

The outer extrusion 902, like the inner extrusion 900, is also anarcuate structure having an arcuate or curved surface 906 that is convexwith respect to an inner passenger compartment when implemented. Asillustrated, the arcuate surface 906 of the outer extrusion 902 does nothave a uniform curve (it contains one or more bends). However, oneskilled in the art should appreciate that the arcuate surface 906 of theouter extrusion 902 may be substantially or perfectly arcuate withoutdeparting from the scope of the present disclosure. A rigid channel 908may be defined within or proximate to an end of the outer extrusion 902,which allows for cables, lines, such as refrigerant lines, and the liketo be passed through the joiner 106. Walls 923, 925, 929, 931, 933, 939extend from the curved surface 906 and/or rigid channel 908 to create aside panel channel 921, roof panel channel 937, and one or more box beamchannels 927, 935. These walls 923, 925, 929, 931, 933, 939 mayperpendicularly extend from the curved surface 906 and/or rigid channel908, for example. Each of the one or more box beam channels 927, 935houses one or more box beams 306. At least one of the box beam channels927, 935 may be created by walls 923, 925, 929, 931, 933, 939 proximateends of the curved surface 906. The side panel channel 921 is createdproximate to or at an end of the curved surface 906 and the roof panelchannel 937 is created proximate to or at a different end of the curvedsurface 906. One or both of the side panel and roof panel channels 921,937 may be partially created by the curved surface 906 and/or a wall923, 939 of a proximate box beam channel 927, 935. A portion of therigid channel 908 may be used to create either a portion of the sidepanel channel 921 or a portion of the roof panel channel 937, or therigid channel 908 may not form a portion of either the side panelchannel 921 or roof panel channel 937. Moreover, a portion of the rigidchannel 908 may be used to partially create one or more of the box beamchannels 927, 935.

An illustrative method for assembling the extrusions 900, 902 into thejoiner 106 is described as follows. An adhesive may be applied to one ormore box beam(s) 306 and/or box beam channels 903, 905 of the inner andthe outer extrusions 900, 902. The box beam(s) 306 are placedwithin/coupled to the box beam channels 903, 905 of either the inner orouter extrusion 900, 902. The box beam channels of the extrusion (eitherinner or outer) not containing the box beams(s) 306 are coupled to thebox beam(s) 306. Alternatively, the box beam channels of respectiveinner and outer extrusions 900, 902 may be coupled to the box beam(s)308 simultaneously.

Furthermore, the box beams 306 within the joiner 106 may be used to passcables, lines, and the like through the joiner 106. The one or more boxbeams 306 may be disposed in selected locations within the box beamchannels 903, 905, 927, 935 of the inner and outer extrusions 900, 902to provide necessary weight, strength, and structural integrity to thejoiner 106. Thus, each box beam 306 may have a length substantiallyequal to or identical to the length of the structural joiner 106,resulting in a single box beam 306 being implemented within each boxbeam channel 903, 905, 927, 935. However, one skilled in the art shouldappreciate the box beams 306 having different lengths resulting in oneor more box beams 306 being implemented within a single box beam channel903, 905, 927, 935 of the joiner 106.

Unassembled, the box beam 903, 905, 927, 935, side panel 903, 905, 927,935, and roof panel 907, 937 channels of the inner and outer extrusions900, 902 each only partially house the box beam(s) 306, side panel 104,and roof panel 108. When assembled, these channels of the innerextrusion 900 correspond with respective channels of the outer extrusion902 (i.e., 901-921, 903-927, 905-935, 907-937) to fully encapsulate orhouse the box beams(s) 306, portions of the side panel 104, and portionsof the roof panel 108. All or some of the channels (that is the box beam903, 905, 927, 935, side panel 901, 921, roof panel 907, 937, and rigid908 channels) may run parallel or substantially parallel to each otheralong their respective extrusion 900, 902.

As illustrated, the joiner 106 is constructed of two separate anddistinct extrusions 900, 902. However, one skilled in the art shouldappreciate the joiner 106 being constructed of a single unitarystructure that resembles the two extrusions 900, 902 coupled together.Regardless of the construction methodology used, a channel 910 is formedbetween the two arcuate surfaces 904, 906. This channel 910 may be usedto pass materials through the joiner 106, such as cables, refrigerantlines, and the like, for example.

Coupling of the inner and outer extrusions 900, 902, when not a singleunitary structure, may include ensuring respective channels of theextrusions 900, 902 (such as box beam-box beam 903, 905, 927, 935, sidepanel-side panel 901, 921, roof panel-roof panel 907, 937, etc.)substantially or perfectly correspond to or line up with each other.Moreover, coupling of the extrusions 900, 902 may include the use of anadhesive, epoxy, resin, or like light weight, durable bonding material.For example, a structural adhesive, such as Sikaflex® 3131s or 3121soffered by Sika Corporation of Lyndhurst, N.J., a methyl methacrylateadhesive, or a two (2) component adhesive may be used to adjoin portionsof the inner and outer extrusions 900, 902 to the roof panel 108 and thebox beam(s) 306 interspersed between the inner and outer extrusions 900,902 and proximate to the roof panel 108. For further example, astructural adhesive, such as Sikaflex® 3131s or 3121s offered by SikaCorporation of Lyndhurst, N.J., a methyl methacrylate adhesive, or a two(2) component adhesive may be used to adjoin portions of the inner andouter extrusions 900, 902 to the side panel 104. Moreover, a structuraladhesive, such as Sikaflex® 3131s or 3121s offered by Sika Corporationof Lyndhurst, New Jersey, a methyl methacrylate adhesive, or a two (2)component adhesive may be used to adjoin the box beam(s) 306 (which areproximate to the side panel 104) to surfaces 909, 911, 913, 915, 925,929, and 931 of the inner and outer extrusions 900, 902. Yet further, asingle component polyurethane adhesive, such as Sikaflex® 252 or 255,offered by Sika Corporation of Lyndhurst, N.J., may be used to bond thebox beam(s) 306 (which are proximate to the side panel 104) to surfacesof the inner and outer extrusions 900, 902 that form part of thechannels 903, 927.

Core material may be disposed within the channels created by and withinthe inner and outer extrusions 900, 902. The core material may impartfurther structural integrity to the joiner 106. For example, the corematerial may be disposed in the channels 903, 905, 927, 935 that housethe box beams 306 in a way that either completely fills the box beamchannels, forms a barrier between the channel walls 909, 911, 913, 915,917, 919, 923, 925, 929, 931, 933, 939 and the box beam(s) 306, and/orfills the box beam(s) 306. The core material may be a fluid, foam, orother lightweight, durable material.

Referring now to FIG. 10, a roof panel 108 is illustrated according tothe present disclosure. The roof panel 108 may include the first outersheet 302, the second outer sheet 304, and core material 308 disposedbetween the first outer sheet 302 and the second outer sheet 304. Asillustrated, the roof panel 108 may be curved. However, one skilled inthe art should appreciate the roof panel being substantially planarwithout departing from the scope of the present disclosure.

One or more box beams 306 may also be disposed between the first outersheet 302 and the second outer sheet 304 of the roof panel 108. The boxbeam(s) 306 may extend from a first end 1002 to a second end 1004 of theroof panel 108 with exemplary dimensions as described for the modularside panels 104 as described above. Inclusion of the box beam(s) 306within the roof panel 108 may provide added strength to the roof panel108 and may add significant strength and protection in the event of arollover of the modular vehicle. It should be appreciated by thoseskilled in the art that other roof panel constructions may beimplemented for integration with a modular side panel and joiner toconstruct a modular vehicle compartment according to the presentdisclosure. Inclusion of a box beam(s) 306 within the roof panel 108 mayalso allow for harness and refrigerant lines, etc. to be passed throughthe roof panel 108. This may be particularly beneficial when an airconditioning unit is placed atop the roof panel 108.

Referring to FIG. 11, a system 1100 for forming the side (and possiblyroof) panels 104, 108 is disclosed. The system 1100 is configured tolimit delamination of the elements of the panels 104, 108. The outersheets 302 and 304 are created by running glass fiber, mat, or cloththrough a resin (e.g., polyester) bath 1102. In an example, each outersheet 302, 304 may have a thickness of about 0.05 inches to about 0.15inches. The wet outer sheets 302, 304 containing resin are moved toseparate walls of a preformer 1104. At the preformer 1104, the beams310, 312 and the core material 308 are strategically placed at locationsbetween the outer sheets 302, 304. Veils 1106 may be applied to theouter sheets 302, 304 just before or while the wet outer sheets 302, 304enter the preformer 1104. The veils 1106 are additional materials/layersadded to the laminar structure during construction that provideadditional characteristics, such as assisting in the protection of theouter sheets 302, 304 from wear, tear, and other degradation. As theouter sheets 302, 304 are moved through the preformer 1104, thepreformer 1104 applies pressure to exterior sides of the outer sheets302, 304 to press the sheets 302, 304 against the beams 310, 312 and thecore material 308, thereby producing a panel having a desiredcross-section and size. The resulting pressed panel is moved to a heatedsteel die 1108 that maintains the shape of the panel and cures the resinof the panel.

While the heated steel die 1108 is illustrated as being separate fromthe preformer 1104, one skilled in the art should appreciate the heatedsteel die 1108 being integrated within the preformer 1104 withoutdeparting from the scope of the present disclosure. The cured panel ispulled by a puller 1110 from the heated steel die 1108 and sent to acutter 1112, where window holes and wheel well(s) may be cut into thepanel. In an example, after the panel is cured but prior to the panelreaching the cutter 1112, the outer surfaces of the panel may belaminated/finished (not illustrated). That is, a decorativeinterior/exterior surface material may be applied as a finish for afully constructed modular panel prior to cutting of the modular panel.

FIG. 12 illustrates an alternative system 1200 for forming the panels104, 108. An outer sheet 302 is disposed upon a lower press 1202. Abonding agent such as resin, epoxy, or the like is disposed upon anupper surface of the outer sheet 302 (i.e., the surface not contactingthe lower press 1202). Pultrusions 310, 312 and core material 308 arestrategically placed upon the bonding agent covered surface of the outersheet 302 in a manner that addresses weight and structuralconsiderations. Bonding agent is placed upon exposed surfaces of thepultrusions 310, 312 and core material 308. Another outer sheet 304 isdisposed upon the bonding agent covered surfaces of the pultrusions 310,312 and core material 308. An upper press 1204 is brought in contactwith the outer sheet 304, and pressure is applied to the outer sheets302, 304 by the presses 1202, 1204 until a panel according to thepresent disclosure is obtained. Moreover, the presses 1202, 1204 mayintroduce heat to the material interposed therebetween. Addition of heatallows for the curing process to be achieved more rapidly.

Referring to FIG. 13, a still further alternative system 1300 forforming the panels 104, 108 is described. An outer sheet 302 is disposedwithin a vacuum bag 1302. A bonding agent such as resin, epoxy, or thelike is disposed upon an upper surface of the outer sheet 302 (i.e., thesurface not contacting the vacuum bag 1302). Core material 308 is placedupon the bonding agent covered surface of the outer sheet 302 in amanner that addresses weight and structural considerations. Bondingagent is placed upon an exposed surface of the core material 308 andanother outer sheet 304 is disposed upon the bonding agent coveredsurface of the core material 308. Upper and lower presses 1204, 1202 arebrought in contact with the vacuum bag 1302, and pressure is applied tothe outer sheets 302, 304 by the presses 1202, 1204 and vacuum bag 1302(i.e., air is removed from the vacuum bag 1302) until a panel accordingto the present disclosure is obtained. Moreover, the presses 1202, 1204may introduce heat to the material interposed therebetween. Addition ofheat allows for the curing process to be achieved more rapidly. In anexample, the upper press 1204 is not utilized. According to thisexample, the only forces applied to the materials of the panel are fromthe vacuum bag 1302 when air is removed from the vacuum bag 1302.

As described with respect to FIG. 13, materials of the panel are addedinto the vacuum bag 1302 as they are layered. However, one skilled inthe art should appreciate the materials of the panel not being added tothe vacuum bag 1302 until layering of the materials is complete.Moreover, while the illustrated panel produced by the system 1300 doesnot include pultrusions 306, one skilled in the art should appreciatethe panel produced by the system 1300 including pultrusions 306 placedfor weight and structural considerations.

As described with reference to FIGS. 11 through 13, the panels accordingto the present disclosure may be formed with the box beams 310, 312being uncoupled or unattached to each other (i.e., they are attached bythe resin to the outer sheets 302, 304). However, in an alternativeimplementation the box beams 310, 312 may be coupled prior to the boxbeams 310 and 312 being formed in a modular panel with the outer sheets302, 304.

FIGS. 14A through 14D illustrate a mechanism for coupling orthogonallydisposed box beams 306 (illustrated in FIG. 14A) using an insert 1400(illustrated in FIG. 14C). A hole 1402 (illustrated in FIG. 14B) is cutinto a side surface of one of the box beams (either the horizontal beamor the vertical beam). A base portion 1404 of the insert 1400 isfrictionally fit within an end of a box beam. The insert 1400 may bemade of a durable material such as steel, aluminum, or the like. In anexample, the insert 1400 may be attached within the end of the box beamusing a resin, epoxy, adhesive, or the like. An extension portion 1406of the insert is mated to or inserted through the hole 1402 cut out ofthe orthogonal box beam. The extension portion 1406 of the insert 1400inserted through the hole 1402 may be maintained in position usingfriction, or may be held in position using a bonding agent such as aresin, epoxy, adhesive, or the like.

FIGS. 15A and 15B illustrate an alternative mechanism for couplingorthogonal box beams 306 using a bracket 1500. An insert portion 1502 ofthe bracket 1500 is fit within an end of a box beam. Fitting of theinsert portion 1502 of the bracket 1500 within the end of the box beammay occur frictionally, or through the use of a bonding agent such asepoxy, glue, and the like. The bracket 1500 also has an abutment surface1504 that couples to a surface of a box beam orthogonal to the box beamthat has the insert portion 1502 of the bracket 1500 inserted therein.Coupling of the bracket 1500 to the surface of the box beam may occurthrough the use of a bonding agent, such as glue or the like, and/orthrough the use of one or more fasteners 1506 such as rivets, machinescrews, or the like, for example. Moreover, the abutment surface 1504 ofthe bracket 1500 that couples to the surface of the box beam may haveone or more edges extending therefrom that increase the efficiency ofcoupling when using a bonding agent. The bracket 1500 may be a durablematerial such as aluminum, ABS, nylon, or the like, for example.

FIGS. 16A through 16E illustrate a further mechanism for coupling boxbeams 306 using a tee-bracket 1600 (illustrated in FIG. 16A). Asillustrated in FIG. 16B, a portion of a surface at the end of a box beam1602 is removed and a portion of the bracket 1600 is inserted into theend of the box beam 1602 until a surface of the bracket 1600 orthogonalto the portion of the bracket 1600 inserted into the box beam 1602 abutsa surface of the box beam 1602. This may result in the box beam 1602housing more of the bracket 1600 than the other box beams 1604, 1606respectively. The other box beams 1604, 1606 are then coupled toportions of the bracket 1600 not inserted into the box beam 1602. Asillustrated, the box beams 1602, 1604, 1606 are coupled to the bracket1600 in a manner that results in the box beams 1602, 1604, 1606 abuttingeach other. However, one skilled in the art should appreciate the boxbeams 1602, 1604, 1606 being coupled to the bracket 1600 in a mannerthat does not result in the box beams 1602, 1604, 1606 abutting. The boxbeams 1602, 1604, 1606 may be frictionally coupled to the bracket 1600and/or may be coupled to the bracket 1600 using a bonding agent.Moreover, if the box beams 1602, 1604, 1606 are installed to abut, thebox beams 1602, 1604, 1606 may be coupled to one or more abutting boxbeam using a bonding agent, for example.

The outer sheets 302, 304 may be one or more of fiber reinforced plasticor fiber reinforced polymer (FRP), an electrically-conductive polymer,gel coatings, resins, thermoplastic polyolefin (TPO), carbon fiber,aluminum (e.g., stainless), acrylonitrile butadiene styrene (ABS), etc.The outer sheets 302, 304 may also be coated or provide decorativeappeal to the panel 104.

The box beams 306 may be formed of a pultruded combination of fiberglassreinforcements and thermosetting polyester or vinyl ester resin systems,such as those sold under the name EXTREN® by Strongwell Corporation. Thepultruded box beams 306 may provide corrosion resistance, low thermalconductance, low electrical conductance, electromagnetic transparency,light weight, high strength, fire resistance, and/or dimensionalstability to the modular panel 104. The box beams 306 may also be formedof aluminum, steel, wood, acrylonitrile butadiene styrene (ABS), or alike durable material, for example.

While the positions of the box beams 306 in the panel 104 are describedand illustrated in connection with a panel of a vehicle, the box beams306 may be positioned in other locations to provide strength for othertypes of applications. For example, in the case of a solid wall,vertically oriented box beams 310 may be equally spaced along a lengthof the wall, and/or horizontally oriented box beams 312 may be equallyspaced along a height of the wall. In some applications, the locationand position of the box beams 306 are tailored to areas where additionalcomponents may be connected to and supported by the panel 104 or otherstructure formed in a similar manner as the panel 104.

Further, while the pultruded box beams 306 are described and illustratedas having a square or rectangular cross-sectional shape, the box beams306 may have other cross-sectional shapes. For example, the box beams306 may have triangular, trapezoidal, or other polygonal cross-sectionsthat have appropriate strength and surface area.

The core material 308 may be a foam, or other material. In one example,the core material 308 may be a light weight fill material, such as, foamsheets, polymer sheets, honeycomb polymer or metal, injectable foam orpolymer. The core material 308 may be polyurethane, polystyrene or otherlight weight polymer in any form (foam, honeycomb, sheet, injectable,etc.), balsa wood, and other lightweight materials. The core material308 may also be selected to provide certain properties. For example, thecore material 308 may be selected to provide additional strength,corrosion resistance, thermal insulation, etc.

Although the chassis herein is described as having a “u-shaped” channelfor receiving edges of side panels, it should be appreciated that theu-shaped channels could include other geometries and features tofacilitate interconnection of the side panels to the chassis.

The above embodiments of the present disclosure are meant to beillustrative. They were chosen to explain the principles and applicationof the disclosure and are not intended to be exhaustive or to limit thedisclosure. Many modifications and variations of the disclosedembodiments may be apparent to those of skill in the art. Moreover, itshould be apparent to one skilled in the art, that the disclosure may bepracticed without some or all of the specific details and stepsdisclosed herein.

FIGS. 17A-17M illustrate major aspects of construction of a modularparatransit bus according to the disclosure. A cab 103 is generallyreceived as a constructed assembly from a vehicle manufacturer such asChrysler®, Ford®, General Motors®, or Promaster®, and a chassis 102having u-shaped channels 200 is mechanically fastened to the cab 103. Inthis illustrative embodiment the cab 103 is configured with beamreceivers 1700 and the chassis 102 is configured with protruding beams1702 for insertion into the beam receivers 1700 (illustrated in FIG.17A). Mechanical fasteners such as nuts/bolts, welds, or the like may beimplemented to retain the beams 1702 in the beam receivers 1700.

FIGS. 17B and 17C illustrate installation of a front panel 1704 to thecab 103 and the chassis 102. The front panel 1704 is placed centrallyalong a width of the cab 103 and/or the chassis 102. Shims may be usedto properly align the front panel 1704. The front panel 1704 may befastened to the cab 103 and/or the chassis 102 using an adhesive 1706.For example, a bead of adhesive 1706 may be layered along a back surfaceof the cab 103, a top surface of the chassis 102 proximate the backsurface of the cab 103, and/or surfaces of the front panel 1704 thatmate with surfaces of the cab 103 and chassis 102 once installed.Additionally or alternatively, other fasteners, such as nuts/bolts,screws, or the like may be used to couple the front panel 1704 to thecab 103 and/or chassis 102. In an example, three (3) screws are used tocouple the front panel 1704 to a bulkhead panel of the cab 103.

FIGS. 17D through 17F illustrate installation of the roof panel 108 ontoinner extrusions 900 of structural joiners 106. As illustrated in FIG.17D, the structural joiners may be held in a a jig or frame so thatpultrusions or box beams 306 are inserted into channels of the innerextrusions 900. The pultrusions 306 may be held into the channels usingclamps, such as deep throat clamps, for example. In an example, thepultrusions 306 may be bonded to the inner extrusions 900 using anadhesive, such as the adhesive 1706.

FIGS. 17G through 171 illustrate coupling of the inner extrusions 900 ofthe structural joiner 106 to the side panels 104. Each side panel 104 ismated to walls of the support channel 901 of an inner extrusion 900. Theside panel 104 may be coupled to a support channel 901 using anadhesive, such as the adhesive 1706. If an adhesive is used, clamps,such as deep throat claims, may be used to hold the side panels 104 andinner extrusions 900 together to ensure adequate coupling.

FIG. 17J illustrates installation of the outer extrusions 902. Eachouter extrusion 902 has box beam channels 927, 935 that receive the boxbeams 306. Each outer extrusion 902 also has surfaces that mate with andcouple to the roof panel 108 and a side panel 104 respectively. Couplingof the outer extrusions 902 of the joining structure 106 to the boxbeams 306, roof panel 108, and side panels 104 may involve the use of anadhesive and/or mechanical fasteners, such as screws, nuts/bolts, welds,or the like.

FIGS. 17K and 17L illustrates installation of side and roof panels 104,108 onto the chassis 102. Portions of the side panels 104 are receivedby the u-shaped channels 200 of the chassis 102. Coupling of the sidepanels 104 to the u-shaped channels 200 may involve the use of anadhesive and/or mechanical fasteners, such as screws, nuts/bolts, welds,or the like. A downward force may be applied to the top of the roofpanel 108 and an upward force may be applied to the bottom of thechassis 102 to ensure adequate coupling of the side panels 104 to thechassis 102. Moreover, shims may be used to ensure the side panels 104are positioned desirable within the u-shaped channels 200.

FIG. 17M illustrates an assembled modular paratransit bus according tothe disclosure. A back panel 1708 may be coupled to back portions of theroof panel 108 and side panels 104. Coupling of the back panel 1708 mayinvolve the use of an adhesive.

There are several types of adhesives that may be used during assembly ofthe modular paratransit bus of the present disclosure. For example, amoisture cured, single or double component, polyurethane adhesive may beused. Such a polyurethane adhesive may include Sikaflex® 252 FC, offeredby Sika Corporation of Lyndhurst, N.J. Alternatively or in addition, amethyl methacrylate, two (2) component structural adhesive or two (2)component epoxy may be used. An example of a suitable two (2) componentstructural adhesive is Sikafast® 3131s, offered by Sika Corporation ofLyndhurst, N.J.

FIG. 18 illustrates a series of steps in construction of a modularvehicle using components as described herein. At block 1800, the cab iscoupled to the chassis. At block 1802, the front panel is coupled to thecab and the chassis. At block 1804, the roof panel is coupled to theinner extrusions structural joiner. At block 1806, the side panels arecoupled to the inner extrusions of the structural joiner. At block 1808,the outer extrusions are coupled to the roof panel, box beams, and sidepanels. At block 1810, the roof and side panels are coupled to thechassis and front panel. At block 1812, the back panel is coupled to theroof and side panels.

The concepts disclosed herein may be applied within a number ofdifferent devices and systems, including, for example, vehicles,watercraft, residential construction, commercial construction, etc. Thespecification and drawings are, accordingly, to be regarded in anillustrative rather than a restrictive sense. It should, however, beevident that various modifications and changes may be made thereuntowithout departing from the broader spirit and scope of the disclosure asset forth in the claims.

What is claimed is:
 1. A modular vehicle, comprising: a chassisincluding a first channel that extends along a first edge of the chassisand a second channel that extends along a second edge of the chassis; adriver compartment coupled to the chassis; and a passenger compartmentcoupled to the driver compartment and the chassis, the passengercompartment comprising: a first side panel coupled to the first channel;a second side panel coupled to the second channel; a first joinercoupled to the first side panel distal from the first channel; a secondjoiner coupled to the second side panel distal from the second channel;and a roof panel including a first portion and a second portion, thefirst portion being coupled to the first joiner and the second portionbeing coupled to the second joiner.
 2. The modular vehicle of claim 1,wherein: the first channel has a length substantially equal to a lengthof the first side panel; and the second channel has a lengthsubstantially equal to a length of the second side panel.
 3. The modularvehicle of claim 1, wherein: the first joiner has a length substantiallyequal to a length of the first side panel; and the second joiner has alength substantially equal to a length of the second side panel.
 4. Themodular vehicle of claim 1, wherein both the first and second channelsare U shaped.
 5. The modular vehicle of claim 1, wherein: the firstchannel consists of a first bottom portion and a first exterior side;the first side panel is adhesively bonded to at least one of the firstbottom portion or the first exterior side; the second channel consistsof a second bottom portion and a second exterior side; and the secondside panel is adhesively bonded to at least one of the second bottomportion or the second exterior side.
 6. The modular vehicle of claim 1,wherein: the first channel consists of a first bottom portion and afirst interior side; the first side panel is adhesively bonded to atleast one of the first bottom portion or the first interior side; thesecond channel consists of a second bottom portion and a second interiorside; and the second side panel is adhesively bonded to at least one ofthe second bottom portion or the second interior side.
 6. A method forassembling a modular vehicle, comprising the steps of: coupling a drivercompartment to a chassis, the chassis including a first channel thatextends along a first edge of the chassis; coupling a first side panelto the first channel, the first side panel including pultruded beamsthat bare weight; coupling a first joiner to the first side panel at alocation of the first side panel distal from the first channel; andcoupling a roof panel to the first joiner.
 8. The method of claim 7,wherein: the first channel consists of a bottom portion and an exteriorside; and coupling of the first side panel to the first channel includesbonding the first side panel to at least one of the bottom portion orthe exterior side.
 9. The method of claim 7, wherein: the first channelconsists of a bottom portion and an interior side; and coupling of thefirst side panel to the first channel includes bonding the first sidepanel to at least one of the bottom portion or the interior side. 10.The method of claim 7, wherein coupling of the first joiner to the firstside panel includes coupling an inner extrusion of the first joiner toan inner surface of the first side panel and coupling an outer extrusionof the first joiner to an outer surface of the first side panel.
 11. Themethod of claim 7, wherein coupling of the first joiner to the roofpanel includes coupling an inner extrusion of the first joiner to aninner surface of the roof panel and coupling an outer extrusion of thefirst joiner to an outer surface of the roof panel.
 12. The method ofclaim 7, wherein the first joiner includes an inner extrusion and anouter extrusion, and further comprising interspersing a first pultrudedbeam and a second pultruded beam between the inner and outer extrusions,the first pultruded beam being located proximate to the first side paneland the second pultruded beam being located proximate to the roof panel.13. The method of claim 7, wherein the chassis includes a second channelthat extends along a second edge of the chassis, and further comprising:coupling a second side panel to the second channel, the second sidepanel including pultruded beams that bare weight; coupling a secondjoiner to the second side panel at a location of the second side paneldistal from the second channel; and coupling the roof panel to thesecond joiner.
 14. A modular vehicle, comprising: a chassis including afirst channel that extends along a first edge of the chassis; and apassenger compartment comprising: a first side panel coupled to thefirst channel, the first side panel including pultruded beams that bareweight; a first joiner coupled to the first side panel distal from thefirst channel, the first joiner including an inner extrusion coupled toan inner surface of the first side panel and an outer extrusion coupledto an outer surface of the first side panel, the first joiner furtherincluding pultruded beams interspersed between the inner and outerextrusions; and a roof panel including a first portion coupled to thefirst joiner.
 15. The modular vehicle of claim 14, wherein: the firstchannel consists of a bottom portion and an exterior side; and couplingof the first side panel to the first channel includes bonding the firstside panel to at least one of the bottom portion or the exterior side.16. The modular vehicle of claim 14, wherein: the first channel consistsof a bottom portion and an interior side; and coupling of the first sidepanel to the first channel includes bonding the first side panel to atleast one of the bottom portion or the interior side.
 17. The modularvehicle of claim 14, wherein the pultruded beams of the first joinerhave lengths substantially commensurate with a length of the firstjoiner.
 18. The modular vehicle of claim 14, wherein at least one of thepultruded beams is proximate the first side panel and has a lengthsubstantially commensurate with a length of the first side panel. 19.The modular vehicle of claim 14, wherein at least one of the pultrudedbeams is proximate the roof panel and has a length substantiallycommensurate with a length of the roof panel.
 20. The modular vehicle ofclaim 14, wherein the chassis includes a second channel that extendsalong a second edge of the chassis, and the passenger compartmentfurther comprises: a second side panel coupled to the second channel,the second side panel including pultruded beams that bare weight; asecond joiner coupled to the second side panel distal from the firstchannel, the second joiner including an inner extrusion coupled to aninner surface of the second side panel and an outer extrusion coupled toan outer surface of the second side panel, the second joiner furtherincluding pultruded beams interspersed between the inner and outerextrusions of the second joiner; and the roof panel includes a secondportion coupled to the second joiner.